Equipment transport assembly for drilling operations and method of transporting equipment

ABSTRACT

An equipment transport assembly for drilling operations includes at least one drilling operation component. Also included is a module structure including an interior region dimensioned to receive the at least one drilling operation component therein, wherein the module structure is configured to be loaded with the at least one drilling operation component at a location for transport to a remote underwater drilling site. Further included is at least one laser located proximate the underwater drilling site and configured to detect the size and position of the module structure and the at least one drilling operation component. Yet further included is a robot located at the underwater drilling site and configured to unload the at least one drilling operation component from the module structure and maneuver the at least one drilling operation component to be operatively coupled to an underwater drilling rig.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application which claims benefitunder 35 USC §119(e) to U.S. Provisional Applications Ser. No.62/019,621 filed Jul. 1, 2014, entitled “EQUIPMENT TRANSPORT ASSEMBLYFOR DRILLING OPERATIONS AND METHOD OF TRANSPORTING EQUIPMENT” which isincorporated herein in their entirety.

FIELD OF THE INVENTION

This invention relates generally to onshore or offshore drilling systemsand, more particularly, to equipment transport assembly for drillingoperations, as well as a method of transporting equipment with theassembly from a location to a remote drilling site.

BACKGROUND OF THE INVENTION

Drilling for hydrocarbons (e.g., oil and gas) involves unique challengesand numerous components and sub-assemblies to effectively carry outdrilling and extraction operations. While onshore and offshore drillingoperations share a few common challenges, they also involve distinctissues associated with operations. In either event, inspection, assemblyand testing of many components involved with the drilling process oftenoccur on site. There are various disadvantages to performing certaintasks on site, particularly for offshore applications that are commonlysubject to harsh environmental conditions. Often, operations must beinterrupted during extreme weather conditions, which involve hazardoustasks and high costs.

In view of the foregoing challenges, efforts have been made to overcomethe challenges by using a seabed rig that is partially or fullysubmerged. The prior efforts use large structures that are typicallysupported by the well and often require a surface vessel to bepositioned directly over the seabed rig. Additionally, certain tasksrelated to inspection, assembly and testing of equipment may bedifficult to perform on a vessel. Delivery of equipment to theunderwater seabed rig is also challenging when conducted on a vessel.

SUMMARY OF THE INVENTION

In one embodiment, a method of transporting equipment for drillingoperations is provided. The method includes loading at least onedrilling operation component into a module structure. The method alsoincludes transporting the module structure from a location to a remotedrilling site. The method further includes detecting a size and aposition of the module structure and the at least one drilling operationcomponent with at least one laser located proximate the remote drillingsite and module structure with component location. The method yetfurther includes maneuvering the at least one drilling operationcomponent with a robot from the module structure into operative couplingwith a drilling rig.

In another embodiment, an equipment transport assembly for drillingoperations includes at least one drilling operation component. Alsoincluded is a module structure including an interior region dimensionedto receive the at least one drilling operation component therein,wherein the module structure is configured to be loaded with the atleast one drilling operation component at location for transport to aremote underwater drilling site. Further included is at least one laserlocated proximate the underwater drilling site and configured to detectthe size and position of the module structure and the at least onedrilling operation component. Yet further included is a robot located atthe underwater drilling site and configured to unload the at least onedrilling operation component from the module structure and maneuver theat least one drilling operation component to be operatively coupled toan underwater drilling rig.

In yet another embodiment, an equipment transport assembly for drillingoperations includes a plurality of drilling operation components. Alsoincluded is a module structure having a plurality of compartments, eachof the plurality of compartments sized to receive one of the pluralityof drilling operation components, wherein the module structure isconfigured to be loaded with the plurality of drilling operationcomponents at a location for transport to a remote drilling site.Further included is at least one locking element disposed in each of theplurality of compartments to secure the plurality of drilling operationcomponents in a fixed position within the plurality of compartmentsduring transport from the remote location to the drilling site.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention, together with further advantages thereof, may best beunderstood by reference to the following description taken inconjunction with the accompanying figures by way of example and not byway of limitation, in which:

FIG. 1 is a top plan view of an equipment transport assembly fordrilling operations;

FIG. 2 is an end view of the equipment transport assembly of FIG. 1;

FIG. 3 is a schematic illustration of an underwater drilling rigassembly located on a seabed;

FIG. 4 is a schematic top plan view of the underwater drilling rigassembly;

FIG. 5 is a schematic illustration of the underwater drilling rigassembly with a mast raised for drilling into the seabed;

FIG. 6 is a schematic illustration of the equipment transport assemblyof FIG. 1 used in conjunction with the underwater drilling rig assembly;and

FIG. 7 is a top plan view of the equipment transport assembly of FIG. 1loaded onto a surface of the underwater drilling rig assembly.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to embodiments of the invention,one or more examples of which are illustrated in the accompanyingdrawings. Each example is provided by way of explanation of theinvention, not as a limitation of the invention. It will be apparent tothose skilled in the art that various modifications and variation can bemade in the invention without departing from the scope or spirit of theinvention. For instance, features illustrated or described as part ofone embodiment can be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the invention cover suchmodifications and variations that come within the scope of the appendedclaims and their equivalents.

Referring to FIGS. 1 and 2, an equipment transport assembly 100 isillustrated. The equipment transport assembly 100 is employed totransport drilling equipment (e.g., hardware, tools, casings, etc.) in astored arrangement from a remote location to a drilling site. The remotelocation may be any location where drilling equipment is prepared forrunning and drilling a well. This advantageously allows for inspection,assembly and testing onshore in a convenient location where theenvironment can be controlled, rather than on-site preparation, assemblyand testing of numerous components, which can include challenges if thedrilling site is subject to harsh environmental conditions in an onshoreor offshore application. In addition to harsh environmental conditionsfor offshore drilling sites, challenges relating to preparing,assembling and testing on a vessel are often present. Due to uniquechallenges associated with offshore drilling sites, the descriptionbelow is directed toward an offshore application, specifically anunderwater drilling rig assembly 10 (FIGS. 3-7), but it is to beunderstood that the equipment transport assembly 100 may be used inconjunction with any onshore drilling application and alternativeoffshore drilling applications.

The equipment transport assembly 100 is configured to store, transportand deliver various equipment modules from the remote location to thedrilling site. The equipment transport assembly 100 includes a modulestructure 102 having at least one, but typically a plurality ofcompartments 104. Each of the compartments 104 is configured to receiveat least one component 106 to be transported to the drilling site. Theat least one component 106 may be numerous contemplated components, suchas a drilling assembly that includes components related to specificdrilling operations. For example, drilling tubular segments, drillpipes, drill bits, a subsea wellhead, casing equipment, etc., may beloaded into the compartments 104 of the module structure 102. Thepreceding list of examples is merely illustrative and is not intended tobe limiting.

The module structure 102 includes at least one locking element tosecurely fix the position of the at least one component 106 storedwithin the compartment 104. In the illustrated embodiment, a pluralityof side locking elements 108 are included to fix the position of the atleast one component 106 in a first direction 110. At least one toplocking element 112 is included to fix the position of the at least onecomponent 106 in a second direction 114. In one embodiment, theplurality of side locking elements 108 and/or the at least one toplocking element 112 are adjustable to accommodate components ofdifferent sizes that are to be loaded into the compartments 104 of themodule structure 102. As shown, the compartments 104 may be defined by aplurality of panels that may be adjustable to customize the size and/ordimensions of each compartment 104.

Referring to FIGS. 3 and 4, as described above, in one embodiment theequipment transport assembly 100 is employed to deliver drillingequipment to the underwater drilling rig assembly 10. The underwaterdrilling rig assembly 10 is depicted in a submarine environment. Thisenvironment, which may be referred to as “undersea” or “subsea,” can beany underwater environment in which is there is a sea floor 12 and awater surface 14. Such environments include freshwater seas and lakes,as well as offshore oceanic environments. The underwater drilling rigassembly 10 may be employed at a deepwater drilling location or in arelatively shallow body of water. The underwater drilling rig assembly10 is particularly beneficial in bodies of water that are prone to iceformation therein and bodies of water that are commonly subjected toharsh environment conditions at the water surface 14. The harshenvironment conditions may include severe weather, including thepresence of high wind, large waves, precipitation and/or bodies of ice,any of which would pose challenges to a first surface vessel 16.

The underwater drilling rig assembly 10 can be transported to thedrilling site by towing or by transport on a lift vessel. Typically, theunderwater drilling rig assembly 10 is transported in a fully assembledform; however, transport as a plurality of components with on-siteassembly is contemplated. Irrespective of the form of transport, theunderwater drilling rig assembly 10 is installed on the sea floor 12 andconfigured to carry out drilling operations on the sea floor 12, therebyovercoming the issues associated with surface vessel or platformdrilling operations in harsh environment conditions.

The following description pertains to a structure and method totransport, install, and operate the underwater drilling rig assembly 10.The underwater drilling rig assembly 10 includes a hull 18 that isbuoyant and configured to float at the water surface 14, if desired.Ultimately, the underwater drilling rig assembly 10 is lowered from thewater surface 14 in a controlled descent to a location proximate the seafloor 12 with any suitable mechanism. The underwater drilling rigassembly 10 includes a moonpool 19 that extends through the hull 18 andis positioned over a desired drilling location on the sea floor 12. Itis to be appreciated that all aspects of the transport, installation,and operation of the underwater drilling rig assembly 10 may bemonitored with an underwater remote operated vehicle (ROV) 20. The ROV20 typically provides a video feed to a human operator that visuallymonitors the process.

The underwater drilling rig assembly 10 also includes a rig assembly 22operatively coupled to, and disposed on, the hull 18. The rig assembly22 includes a number of components and structures that are typicallyassociated with drilling operations. In one embodiment, the underwaterdrilling rig assembly 10 is similar to a jack-up structure, but theentire assembly is configured to be submerged and placed on the seafloor 12, as described in detail herein. The hull 18 is configured to beballasted proximate the sea floor 12. Extending from the hull is atleast one, but typically a plurality of legs 24 extending from the hull18 toward the sea floor 12. In one embodiment, three such legs areincluded to provide desired stability, but more or less arecontemplated. The legs 24 are lowered to engage the sea floor 12 and theload of the underwater drilling rig assembly 10 is transferred to thelegs 24. It is to be appreciated that the plurality of legs 24 bear theoverall load of the underwater drilling rig assembly, specifically thehull 18 and the rig assembly 22. This is in contrast to a wellheadsupporting a drilling assembly. The legs 24 can be adjusted tocompensate for a sea floor region that is not level. The adjustment, ifneeded, provides an overall leveling of the hull 18, and therefore theunderwater drilling rig assembly 10 overall. In one embodiment, aplurality of spud cans 26 are installed proximate ends of the pluralityof legs 24 to provide further anchoring and self-leveling of theunderwater drilling rig assembly 10, however, this may not be requiredin certain applications.

Referring now to FIG. 5, with continued reference to FIGS. 3 and 4, therig assembly 22 includes a mast and pipe lifting arm module 28. Uponproper securement of the underwater drilling rig assembly 10 to the seafloor 12, a mast 30 of the mast and pipe lifting arm module 28 is raisedfrom the illustrated horizontal position (FIG. 3) to a substantiallyvertical position (FIG. 5) to facilitate various lifting and drillingoperations performed by the underwater drilling rig assembly 10. Asshown, the mast 30 is maneuverable between substantially horizontal andvertical orientations. Such a feature may be particularly beneficial inbodies of water having an ice keel that protrudes to depths of the bodyof water that may interfere with the underwater drilling rig assembly10. If such a condition is detected, the mast 30 is simply maneuvered toa substantially horizontal position. A pipe handling unit 34 of the mastand pipe lifting arm module 28 is configured to be pivoted from thehorizontal position (FIG. 3) to facilitate maneuvering of a drill pipe(not shown) to be operatively coupled to the mast 30. A drill bitassembly (not shown) is lowered into a desired position and operativelycoupled to the mast 30.

A control unit 42 is installed at a location proximate the sea floor 12and the rig assembly 22. In the illustrated embodiment, the control unit42 is integrated with the rig assembly 22 on the hull 18. Alternatively,the control unit 42 may be placed directly on the sea floor 12. Thecontrol unit 42 includes a plurality of components configured to carryout various tasks associated with overall operation of the underwaterdrilling rig assembly 10. The specific tasks are numerous and thefollowing are merely illustrative of the contemplated tasks. The controlunit 42 includes various lines, such as at least one return line 44operatively coupled to the surface vessel 16 and the control unit 42.The return line 44 is configured to return fluids, such as drillingfluid and waste fluid to the surface vessel 16 from the underwaterdrilling rig assembly 10. Additionally, at least one supply line 46 isoperatively coupled to the surface vessel 16, as well as one or morecomponents of the rig assembly 22, including the control unit 42. Thesupply line(s) 46 comprise a flow line to provide drilling fluid and anelectrical line to provide power to the underwater drilling rig assembly10. To facilitate routing of fluid, the control unit 42 includes a pumpconfigured to direct the fluid in a desired direction. The control unit42 further includes a plurality of cables (not shown) extending from thecontrol unit 42, each of the cables connected to components of theunderwater drilling rig assembly 10. Such a connection between thesurface vessel 16, the control unit 42, and various components of theunderwater drilling rig assembly 10 allows remote control of variousfunctions of the underwater drilling rig assembly 10. The configurationof the lines extending between the control unit 42 and the surfacevessel 16 is such that the surface vessel 16 does not need to remaindirectly over the underwater drilling rig assembly 10. By providingflexibility regarding the positioning of the surface vessel 16,challenges associated with maintaining precise position of the surfacevessel 16 are avoided. This is particularly advantageous in severeweather environments.

In addition to a physical connection with the above-described lines andcables, a wireless connection may be present between the control unit 42and the surface vessel 16 and/or the components of the underwaterdrilling rig assembly 10. By remotely controlling the underwaterdrilling rig assembly 10 with the surface vessel 16, it is not necessaryto have human operators in direct physical contact with the underwaterdrilling rig assembly 10. In addition to remote control of the assembly,numerous aspects of operation of the underwater drilling rig assembly 10may be automated, as is the case with onshore drilling assemblies. Inparticular, an automated drilling mode is enabled with the underwaterdrilling rig assembly 10. Once the underwater drilling rig assembly 10is fully installed and operational, the drill bit assembly initiatesdrilling into the sea floor 12. After reaching a sufficient depth withthe drill bit assembly, a casing may be installed within the hole and ablowout preventer (BOP) may be run and installed proximate a wellhead ofthe hole.

Referring now to FIG. 6, the equipment transport assembly 100 isillustrated in use with the underwater drilling rig assembly 10.Illustrated are the first surface vessel 16 and a second surface vessel17. The first surface vessel 16 is used to remotely control and interactwith the underwater drilling rig assembly 10, as described in detailabove. The second surface vessel 17 is a heavy lift vessel configured totransport the equipment transport assembly 100. More specifically, thesecond surface vessel 17 is used to transport one or more modulestructures 102 loaded with drilling components. In addition totransporting and delivering the module structures 102, the secondsurface vessel 17 may be configured to be a standby support vessel forthe first surface vessel 16.

The second surface vessel 17 includes a moonpool (not shown) that isformed in the base of the hull to provide access to the body of water.The moon pool provides an entry and exit location for deployment andrecovery of the module structures 102 at the drilling site. As shown,each module structure 102 is deployed in a controlled descent that isfacilitated by one or more buoyancy modules 116. Once the modulestructure 102 has descended to a depth proximate a landing location 118of the underwater drilling rig assembly 10, the module structure 102 isrotated, as needed, to align with landing seats (not shown) on the rig.

Referring to FIG. 7, a top view of the underwater drilling rig assembly10 is shown with the equipment transport assembly 10 illustrated in aposition on the landing location 118. Once in position, size andpositional data of the module structure 102 and the components 106loaded therein is obtained with a laser configured to map thestructures. The laser generating structure is integrated with theunderwater drilling rig assembly 10 and is configured to transmit theobtained size and positional data to a robot 120 via a wired or wirelessconnection. Specific lifting and placement instructions are generatedand provided to the robot 120 based on the size and positional data. Therobot 120 then is actuated to carry out the instructions and isconfigured to place the equipment in various places depending on theparticular component. Typically, the robot 120 places the component 106in position for pick-up by the pipe handling unit 34 of the underwaterdrilling rig assembly 10. The pipe handling unit 34 then maneuvers thecomponent 106 as needed and as described in detail above.

Once all operations related to the particular module structure locatedon the landing location 118 have concluded, the module structure 102 issent back to the second surface vessel 17. In some cases, the modulestructure 102 may be loaded again and sent back to the second surfacevessel 17.

Advantageously, the equipment transport assembly 100 further facilitatesautomation of the underwater drilling rig assembly 10, thereby enablingthe assembly to be remotely operated by as little as one human operator.The hull 18, and therefore the entire underwater drilling rig assembly10, rests on the sea floor 12, thereby allowing loading of the othercomponents to be on the base, rather than on the well itself.Furthermore, based on the remote control of the underwater drilling rigassembly 10, the surface vessel(s) supporting the assembly are notrequired to be positioned directly over the assembly and the well. Thisis particularly advantageous in harsh weather conditions, includingthose where ice formation is present at the water surface 14 of the bodyof water. Conducting the drilling operations on the sea floor 12overcomes several obstacles with drilling in such environments. Indeepwater drilling locations, the above-described embodiments obviatethe need for the long length of a drilling riser that would normallyextend from the first surface vessel 16 to the sea floor 12.

While the invention has been described in detail in connection with onlya limited number of embodiments, it should be readily understood thatthe invention is not limited to such disclosed embodiments. Rather, theinvention can be modified to incorporate any number of variations,alterations, substitutions or equivalent arrangements not heretoforedescribed, but which are commensurate with the spirit and scope of theinvention. Additionally, while various embodiments of the invention havebeen described, it is to be understood that aspects of the invention mayinclude only some of the described embodiments. Accordingly, theinvention is not to be seen as limited by the foregoing description, butis only limited by the scope of the appended claims.

What is claimed is:
 1. A method of transporting equipment for drillingoperations comprising: loading at least one drilling operation componentinto a module structure; transporting the module structure from alocation to a remote drilling site; detecting a size and a position ofthe module structure and the at least one drilling operation componentwith at least one laser located proximate the remote drilling site; andmaneuvering the at least one drilling operation component with a robotfrom the module structure into operative coupling with a drilling rig.2. The method of claim 1, wherein loading the at least one drillingoperation component comprises loading a plurality of components into aplurality of compartments of the module structure.
 3. The method ofclaim 1, further comprising locking the at least one drilling operationcomponent with a locking element to restrain movement of the at leastone drilling operation component within the module structure duringtransport.
 4. The method of claim 1, wherein the at least one drillingoperation component comprises tubular components to be used within ahole at the remote drilling site.
 5. The method of claim 1, wherein theremote drilling site is an underwater drilling rig assembly.
 6. Themethod of claim 1, wherein the remote drilling site is an onshoredrilling site.
 7. The method of claim 1, further comprising transmittingsize a positional data detected with the laser to the robot.
 8. Anequipment transport assembly for drilling operations comprising: atleast one drilling operation component; a module structure including aninterior region dimensioned to receive the at least one drillingoperation component therein, wherein the module structure is configuredto be loaded with the at least one drilling operation component at aremote location for transport to an underwater drilling site; at leastone laser located proximate the underwater drilling site and configuredto detect the size and position of the module structure and the at leastone drilling operation component; and a robot located at the underwaterdrilling site and configured to unload the at least one drillingoperation component from the module structure and maneuver the at leastone drilling operation component to be operatively coupled to anunderwater drilling rig.
 9. The equipment transport assembly of claim 8,wherein the at least one drilling operation component comprises aplurality of components and the module structure comprises a pluralityof compartments configured to receive at least one of the plurality ofcomponents.
 10. The equipment transport assembly of claim 9, wherein theplurality of components comprises equipment to be used within a hole atthe underwater drilling site.
 11. The equipment transport assembly ofclaim 8, further comprising at least one locking element configured tosecure the at least one drilling operation component in a fixed positionwithin the interior region of the module structure during transport fromthe remote location to the underwater drilling site.
 12. The equipmenttransport assembly of claim 8, wherein the at least one laser is inoperative communication with the robot.
 13. The equipment transportassembly of claim 12, wherein the robot is configured to receive sizeand positional data for the module structure and the at least onedrilling component.
 14. An equipment transport assembly for drillingoperations comprising: a plurality of drilling operation components; amodule structure having a plurality of compartments, each of theplurality of compartments sized to receive one of the plurality ofdrilling operation components, wherein the module structure isconfigured to be loaded with the plurality of drilling operationcomponents at a remote location for transport to a drilling site; and atleast one locking element disposed in each of the plurality ofcompartments to secure the plurality of drilling operation components ina fixed position within the plurality of compartments during transportfrom the remote location to the drilling site.
 15. The equipmenttransport assembly of claim 14, wherein the drilling site is anunderwater drilling site comprising an underwater drilling rig.
 16. Theequipment transport assembly of claim 14, wherein the drilling site isan onshore drilling site.
 17. The equipment transport assembly of claim14, wherein the plurality of drilling operation components comprisesequipment to be used within a hole at the drilling site.
 18. Theequipment transport assembly of claim 14, further comprising: at leastone laser located proximate the drilling site and configured to detectthe size and position of the module structure and the plurality ofdrilling operation components; and a robot located at the drilling siteand configured to unload the plurality of drilling operation componentsfrom the module structure and maneuver the plurality of drillingoperation components to be operatively coupled to a drilling rig. 19.The equipment transport assembly of claim 18, wherein the at least onelaser is in operative communication with the robot.
 20. The equipmenttransport assembly of claim 19, wherein the robot is configured toreceive size and positional data for the module structure and theplurality of drilling components.